Apparatus for making wall board



C. PAYNE July Z3, 1929.

APPARATUS FOR MAKING WALL BOARD Original Filed May l0, 1926 Patented.luly'l 213, 192,2.

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" '5 F F Q LMANUFACTURING C0., 0F CHICAGO,'ILLINOIS, .A CORPORATIQN 0FILLINOIS.

APP.RA'IUS FOR MAKING WALL BOARD.

Uriginal application led May 10, 1926, Serial No. 107,854. Divided andthis application lel August 22,

1927. Serial No. 214,577.

This is a division of my application Serial N o. 107,854 filed May 10,1926.

The primary object of the'invention is to manufacture 'a wall board ofsuperior insu lating quality which is light in weight and strong andsubstantial in structure.

Another objectv of the invention is to form a continuous strip ofprotective material into a trough which moves continuously, as it isformed, in upright position and open at the top toreceive foamaceousmaterial vwhich fills the trough and produces a cellular body, theproduct being cut and dried in lengths suitable for shipping.

And a further object of the inventionis to form the body of t-he wallboard in a trough of protective covering and then seal thc 1edge of thetrough by depositing a sealing material therein.

In the accompanying drawings illustrating diagrammatically a selectedembodiment of the invention:

Fig. 1 is a sectional view of wall board made in accordance with myinvention.

Fig. 2 is an elevation, partly in section, showing diagrammatically anapparatus which may be employed for manufacturing wall board on edge inaccordance with my invention.

Fig. 3 is a similar view of additional apparatus which may be employedin connection with that shown in Fig. 1 for sealing the open edge of thewall board.

Figs. 4 and 5 are sectional views on the 35 lines 4-4 and 5-5respectively of Fig. 1.

Fig. 6 is a longitudinal sectional view of a portion of the board andmeans for protecting the raw edge of the board.

Fig. 7 isa detail sectional view.

I contemplate using as a protective cover- ,ing for my wall board thekind of paper which is now generally used for this purpose in separatesheets to form the sides of wall board. I prefer to rovide the paper ina 45 roll 6 from which itis drawn in the form of a strip or web 7 andfolded by suitable means into a trough 8, Fig. 4, open at the top toreceive the body material. A presser roller 9 and a former 9 may beprovided for fold- 50 ing the web into a trough which travels open edgeupward through'a pouring frame 10. This frame has a plurality ofvertically disupright position for a sufficient time after the bodymaterial is poured thereinto for the body .material to set to an extentwhich will perm1t the further treatment of the board. The two series ofrollers are spaced apart to produce a board of desired thickness andthey are of relatively small diameter'and are set comparatively closetogether to form a suficiently continuous support on each side of thepaper trough to maintain the trough in upright position while the bodymaterial is being poured therein and while the body material is settingsufficiently to enable the board thus formed to be further treated.

I contemplate using a foamaceous material for making a lightweightcellular body for the board. The material is of a pouring conslstencyand is permitted to pour from the receptacle 12 into the trough at orabout the front end of the pouring frame. This material is of` acharacter which will be converted into foam after it enters the trough,and. in foaming the material is distributed in a sub stantially uniformmanner in the trough from top to bottom thereof to form a cellular bodyof uniform cellular structure and uniform thickness. The body sets andbecomes self supporting progresswely in the trough and. if desired, thespace between the rollers'may be progressively increased to correspondwith the progressive setting of the body material;

Y but adjacent the pouring front end ofthe pouring frame the rollersshould be set close together to support the trough in proper po sitionwith parallel sides and to prevent deformation of the sides.

When the board is dischar ed from the pouring frame itmay be cut yasuitable cutter 14 into predetermined lengths 15 which passy from thecutter to a guide 16 of suitable construction, which turns each length15 from an upright to a horizontal position for convenience in runningit through the drier 17. This drier may be of any suitable kind and itis preferably provided with a plurality of passes into which the lengthsthrough the drier at a slower rate of speed than the trough will travelthrough the pouring frame and the board lengths will be cut.

TheJ wall board thus formed will be of a specified width, length andthickness; both sides of the board will have a protective covering ofpaper and one long edge, the bottom of the trough, will have a papercovering.

I But the. upper long edge, the top of theA trough, will be raw; that isto say the body will e exposed. Such a board may be satisfactory forsome purposes, but I prefer to protect this raw edge so that it will beas well finished for commercial purposes as the other long edge, and sothat it will be uniformly straight and parallel with the other longedge. To this end, the pouring frame may be provided at the top withmeans, such as a strip 19, Fig. 5, to fit within the trough at the topthereof and form a guide for the upper edges of the paper covering and awall to form the edge of the body at the open end of the trough. Thisstrip 19 may be located to permit the body to form flush with the upperedges of the trough covering, but I prefer that the strip should projectinto the trough so that the upper edge of the body will be locatedslightly within the trough and below the upper edges of the sides of thetrough,

leaving a recess extending longitudinally ofthe board along theedgethereof and between the edges of the paper covering on the sides of theboard. It is this recess whichv I lill v with a material to protect theedge of the body and the edges of the paper sides of the board. Thefilling material may be compo pulp made of paper pulp anda binder or anyother material suitable for the purpose. A,

When the board length leaves the drier 17, Fig. 3,' in a horizontalposition, it is turned to an upright position by a suitable guide 20with the raw edge of the vboard up. Then the board passes under thedischarge end of of a receptacle 21 Whichcontains the compo ,pulp orother filling material and this material is deposited in the recess atthe upper edgeof the board. A smoother 22, Fig. 6, is supported abovethe board and adjacent the receptacle 21 to remove surplus filler and tosmooth the filler which is deposited upon v'the board. It is desiredthat the material set quickly to till the recess and to form aprotective covering 23 for what would otherwise be a raw edge of theboard. I may provide for depositing the filler on the board to form theprotective strip 23 between the -pouring frame and the cutter, orbetween the cutter and the drier, and the filler may be depositedwhilethe board remains in the pouring frame, the latter frame being extendedif found necessaryr or desirable for the purpose and the receptacle 21and the smoother 22 would then be mounted on or abovethe pouring frameor adjacent thereto.

My invention'provides for the manufacture of a novel wall board which islight in weight, has superior insulating quality, and is capable ofbeing made inlstandard or special sizes. I estimate that wall board madein accordance with my invention will weigh approximately .one-third ofthe weight of corresponding commercial wall board at present in use, andthis is. of special importance in structural material because it enableswall board to be satisfactorily used in large sizes. A wallboard of.large size made in accordance with my invention will permit of handlingwithout distortion or liability of being damaged and hold its shape toan extent and in a manner which is not possible under ordina-ryconditions with wall board of the kind at present manufactured. This isbecause it is so much lighter in weight for a given size than presentcommercial wall board. And its advantages in-this respect increase with`the increase in thickness as well as with the increase in area of thewall board being used. The wall board of my invention has superiorinsulating quality because of the cellular character of the bodyof theboard and while this cellular body may appear to be of delicate andfragile structure, it has suiiicient strength when protected by acovering of paper or other suitable material, as contemplated by myinvention, to be' capable of use for such purposes as wall board may beused and to better advantage and with better results than wall boardof`present manufacture.

I have not attempted to show any means for drawing the covering materialfrom the roll 6 or any means for moving the trough and `the boardthrough the pouring frame, the drier and the 'other parts of theapparatus, or other means, more or less necessary in connection with theapparatus, and which are now in use in different forms for dii'erentpurposes and can be purchased in the open market or -built as requiredand which form no ing upon both sides and upon both edges.

Any adhesive material may be used for affixing the margin 24 to thebody, if this adhesive is found to be necessary or desirable.

I am aware that changes in the form, v'con' struction and arrangement ofthe apparatus and in the materials used and in the structure of the wallboard may be made lwithout departing from the invention and I reservethe rightto make all such changes as fairly fall within the scope of thefollowing claims.

, I claim: 1

1. Apparatus for making wall board with foamaceous material whichcomprises means for folding a strip of covering material into acontinuous forwardly travelling narrow trough, means for supporting saidtrough in upright position, its long closed edge being down and its longopen edge up, and means for pouring body material into said troughthrough the long open topedge thereof.

2. Apparatus for making wall board with foamaceous material whichcomprises means for folding a strip of'covering material into acontinuous forwardly travelling narrow trough, means for supporting said'trough in upright position, its long Aclosed edge being down and itslong open edge up, means for pouring body material into said troughthrough the long open top edge thereof, and a drier aligned with theboard forming means feo receive the board as it leaves the forming.

' means.

3. Apparatus for making wall board with foamaceous material whichcomprises means for folding a strip of `covering material into acontinuous forwardly travelling narrow trough, means for supporting saidtrough in upright position, its long closed edge being down and its longopen edge up, means for pouring body material into' said trough throughthe long open top edge thereof, a drier to receive the board after itleaves pour-V ing position, and means intermediate of the board formingrmeans and the drier for cutf an upright means for supplying a protectivecoverin for the edge of the body at the open end o the trough.

5. Apparatus for making wall board with foamaceous material whichcomprises means for folding a strip of lcovering material into acontinuous forwardly 'travelling narrow trough, means for supportingsaid trough in upright position, its long closed edge being down and itslong open edge up, means for v pouring body material into said troughthrough the long open top edge thereof, and

lmeans for providing a recess at the open edge of the trough between thesides of the covering material on thebody of the board.

6. Apparatus for making wall board with foamaceous material whichcomprises means for folding a strip of covering material into acontinuous forwardly travelling narrow trough, means for supporting said.trough in up right position, its long closed edge being down and itslong open edge up, means for pouring body material into said troughthrough the long open top edge thereof, means for providing a recess latthe open edge of the trough between the edges of the covering materialon the sides of the board, and means for depositing a protectivematerial in said recess to seal .that edge of the board.

7. Apparatus for making wall board with foamaceous material whichcomprises means for folding a strip of covering material into acontinuous forwardly travelling narrow trough, means for supporting saidtrough in 'upright position, its longclosed edge being down 'and itslong open edge up, means for pouring body material into said troughthrough the long open top edge thereof, means forproviding a recess at4,the open edge of the I trough between the edges of the coveringniaterial on the sides of the board, meansfor depositing aprotectivematerial in said recess to seal that edge of the boardand means forsmoothing the protective material after it is deposited. H CALEB PAYNE.

